Process of forming slag blocks



Jan. 12, 1937 w c CORYELL 2,067,313

PRQCESSOF FORMING SLAG BLOCKS Original Filed June 29, 1933 2 Sheets-Sheet 1 ff Snventor 74L M ZZ,

' 1937 w. c. CORYELL PROCESS OF FORMING SLAG BLOCKS Original Filed June 29, 1933 2 Sheets-Sheet 2 gwwwwg ttomcg Fatented Jan. 12, 1937 STATES PATENT oFFIc'E" Original application June 29,1933, Serial No. 678,251. Divided and this application May 31,

1935, Serial No. 24,319

3 Claims. (Cl. 49-775) This application contemplates dealing with a molten slag mass and passing the slag as a stream between forming elements which shape the slag to a given cross-section and then, in some cases, breaking ofl slabs or blocks at the cooling end of the stream as the same advances. It also contemplates tongueing and grooving the edges of the block. In some instances this may be done by forming grooves in both edges and then placing a separate strip in one of the grooves and extending it outward far enough to provide the tongue. In other instances the tongue may be formed at the time of forming the block. Again the bar or bars inserted within the groove or grooves of the block will serve as reinforcing bars for the product block or slab. The surfaces "of the block or slab may also be roughed during the forming steps so as to suit the same to the receiving of mortar or the like for plastered surfaces. They may be also treated so as to close over the cellular formations and thus provide a more or less continuous and unbroken surface. These and other like novel steps and products follow in the wake of the new process. One object of the invention is to provide a quick and continuous process for forming the slag or its equivalent while in a more or less hot viscous state, and to this end a slag mass is passed from the mixer along a continuous path and treated at difierent points in its travel. Preferably the travel of the mass is continuous or practically so.

Another object is to form the edges of the advancing slag slab in a definite way, as, for example, flat, or one with a tongue and the other with a groove, or both with grooves. In the latter case a tongue member of similar or quite differentmaterial may be inserted in the one groove to provide a tongued and grooved product.

Another object is to provide a novel way of breaking off the end blocks or pieces from the advancing end of the slab. This is preferably done by transversely creasing the slab on its upper side while it is in a more or less plastic condition and then when it cools breaking ofi the end in advance of the last crease. The weight of the block may be relied upon to do this breaking along the adjacent crease line, or the same may be broken ofi in any other desired way.

Another object is to' give the surfaces of the finished product a more or'less rough yet continuous and unbroken finish. This is preferably done by raking the advancing molten slab after up the'cells at and-near the surface of the viscous material of the slab and causes the adjacent material to come together to provide a rough yet fairly continuous and unbroken surface suitable for the adhesion of a coat of plaster or the like.

These various features and advantages of the invention, together with others, will be more fully understood upon reference to the following detailed description taken in connection with the accompanying drawings while the scope of the invention will be particularly pointed out in the appended claims. I

The present application is a division of my prior application Serial No. 678,251, filed June 29, 1933. Said prior application has to do more particularly with the method of bloating the slag mass. This case has to do, not with the bloating, but with the forming of the same into slabs or blocks.

In said drawings, Fig. 1 is a diagrammatic view partly in section illustrating the method of the invention and suitable apparatus for carry-- ing out the method; Fig. 2 is a plan view of the apparatus illustrated in Fig. 1; Fig. 3 is a view mostly in elevation of the edge forming mechanism by which the grooves are placed in the edge of the slab as it travels along, the few parts in section being cut on a plane indicated by the line 3-3 of Fig. 2; Fig. 4 is a similar view of suitable mechanism for placing sand, or the equivalent, upon the conveyor as it is about to receive the molten slag from the mixing chamber of the apparatus; Fig. 5 is a perspective view of a portion of a block formed according to the present method and having suitable grooves in its edges; Fig. 6 is a similar view of the same block with a tongue member inserted in one of the grooves; Fig. '7 is a similar view of the grooved block showing metal reinforcing "bars or rods cemented into the two grooves; Fig. 8 is an elevation of the edge wheels necessary when both a tongue and groove are to be formed at the time of shaping and molding the issuing slab web; Fig. 9 is a perspective view of a portion .of a block made after the manner illustrated in Fig. 8; Fig. 10 is a perspective view of a portion of a slab block having certain of its faces relatively smooth and free from visible cellular formation and yet rough enough to easily take a coat of plaster; and Fig. 11 is a diagrammatic view illustrating a blast furnace and an associated car and ladle by which hot slag may be supplied to the mixing chamber of the apparatus. Throughout these views like characters refer to like parts.

In brief, the new process comprises bringing the molten slag from a blast furnace A, or other suitable source, for it is not so important just what kind of slag or slag-like material is used, to a. combustion and mixing chamber B. A ladle C is commonly used to convey the molten slag from the source of supply to the mixing chamber, although slag runners may be used if the chamber B be located near the furnace. The molten slag is passed through the combustion and mix 7 ing chamber B in a more or less continuous stream.

As the molten slag is about to enter the chamber B it is supplied with a fuel or other combustion element fed into the stream from a fuel holder D, or fed by hand or otherwise as may be desired. The fuel ingredient E thus delivered from the holder D is preferably a comminuted fuel and it is directed into the molten slag stream near the inlet of the mixing chamber, that is to say, near the beginning of the path of the slag through the chamber. A common form of comminuted fuel obtainable where molten slag is usually produced as a more or less waste product, is pulverized coking coal or coke screenings. Such fuel will be found desirable for the purposes of the present invention.

The next step in the treatment of the advancing slag stream is the introduction and diffusion of oxygen or other combustion promoting element, preferably injected through a tuyere F into the mixing chamber near its bottom. The

fuel and oxygen are Well mixed into the mass of molten slag and as they pass along with the same the fuel is more or less completely burned by reason of the presence of the oxygen and as a result a multiplicity of gas bubbles is formed by the combustion of the particles of fuel. Indeed, a high temperature is produced and this high temperature assists materially in gasifying the fuel particles so that the resulting gas and the supplied oxygen burn vigorously and at times more or less explosively. As the fuel particles travel upward through the molten slag the intermixture of bubbles and slag substances is promoted and the settling of liquid' materials is largely prevented by utilizing the same in the building up of new bubbles. Any ash left from the fuelmerely adds non-combustible material to the slag mass. Any excess air that may be supplied merely adds to the bubble content of the slag. Air or oxygen or other gas furnished through the tuyere F may be supplied from any suitable source, as indicated by the compressed air tank G, the oxygen being obtained from the compressed. air in case of such a supply.

The fuel E may be, as before indicated, a comminuted fuel and the same may be supplied in briquetted dust, small sacks, or otherwise. Such packets E may be injected into the slag stream by hand or carried by an elevator H associated with a supply hopper J.

As the bubbling mass passes out of the chamber B it may be treated further to change its consistency and content. Thus, non-combustible material K may be directed into the slag stream from a suitable holder or hopper L, or by hand or otherwise, as desired. Such material, where non-combustible, may be pulverized slag, pulverized limestone or the like. Where combustible,

it may be any of the fuel materials herein mentioned.

ber. A stirring device M may be provided for this purpose, or a certain amount of stirring may be done by hand. In some instances, stirring will be quite unnecessary, and instead of stirring, heating and other ways of treating the slag to bring about the desired changes in its constituent character may be resorted to. Obviously, the slag may be treated or not treated at this delivery point.

When the slag leaves the combustion and mixing chamber, it is in condition to be shaped and treated in accordance with the steps of the invention disclosed and claimed herein. To this end it is deposited upon a traveling conveyor P. When deposited on the latter, itis suitably formed into an advancing slab web of definite cross-section. The ways of forming the section may vary. In 'the case illustrated, edge forming mechanism Q-comprises edge engaging wheels which determine the width of the web and the shape of itsedges, and then a transverse roller R determines the thickness of the web.

The roller R also bears a creasing bar and once per revolution this bar forms a crease in the upper face of the traveling slab. This means that the creases are formed at regular intervals. As the slab advances it cools and finally the end protrudes beyond the conveyor and ordinarily breaks off by reason of its own weight, although in some cases it may be broken off by the hand at the point indicated, or at some other point as desired. The pieces which are broken off are in the form of slabs or blocks S.

In order to facilitate the removal of the slag from the conveyor P, it is preferable to deposit sand or a like material upon the belt just before it encounters the slag. This material may be deposited by hand if desired, but preferablyit is. distributed over the belt by a sanding device U located just beneath the outlet of the mixing chamber and at the receiving end of the belt.

The blocks or slabs which are formed by breaking off the end of the continuous slab from time to time may be greatly varied in dimensions and formed to suit different classes of service. In Figs. 5, 6, and '7, narrow grooved blocks S are shown. These represent slabs or blocks made in accordance with the method of the present invention. They have grooved edges and are provided variously with metal reinforcing bars and bars which form tongues for tongued and grooved building blocks. In addition, the blocks may be formed with tongues and grooves by the edging rollers. Such a block is the block S of Fig. 9. A plain block without tongues or grooves may also be found. v

Incarrying out my invention, the slag which I employ may have a variety of compositions. It may be the ordinary blast furnace slag. Such slag will diifer inthe case of different blast furnaces. The differences in the different cases will result from the different kinds of ores and the different kinds of materials used in reducing them. The term slag may also be used to include mixtures and compositions which resemble slag in formation, thus various Waste glass products may be mixed together in such ,a way as to form a bubbly mass of molten material and show a cellular structure when cooled." It is not intended to limit the present invention to the treatment of" any particular kind of slag. Indeed, the term is to be used in a broad sense so as to include not only the available blast furnace 'slags and nel 48 and at that time holdthe fuel which has it is drawn off through the usual notch" or outlet l into ladies C. These ladies are presented one after the other at the blast furnace and filled with the slag. Ordinarily, they are carried to the filling point upon a car it although, in some instances, they might be presented at the filling point by a crane. One such car and, carrying a ladle, is shown in Fig. 11, positioned adjacent to the associated apparatus of Fig. 1. way is employed for filling the ladies C with slag, the ladies are ultimately raised by a crane and brought to a position above the mixing chamber B and tilted so as to pour out the contents. In the drawings, crane connections l2 and it are shown. These particular slag handling devices form no part of the present invention and, therefore, need not be more fully disclosed.

The combustion and mixing chamber B may obviously take different forms. It is desirable to confine the molten mass received from the ladies and treat it by supplying the combustion materials at the properpoints and any suitable structure which will accomplish this will be satisfactory for carrying out the steps of the invention.

In the case illustrated, the mixer B comprises an outer metal casing to and an inner structure of fire clay. The latter includes a bottom M of suitable thickness, 9. back d2, shown as of much greater thickness than the bottom, and a front t3, and sides dd and 65, all of a thickness about the same as that of the bottom ti. There is also preferably an overhanging partition 66 of considerable thickness and irregular in contour. The fire clay structure provides a hopper M having a constricted throat or passage 63 and a lower basin 69. From the forward end of the latter there is an upwardly extending passage 50 which terminates in a downwardly extending spout 5i over which the mixed product passes on its way to the conveyor P. The upwardly extending passage 5% of the chamber B is separated from a smaller chamber 52 just beneath the throat 48 by a depending lip 53. The space. between the lower edge of the lip 53 and the bottom M provides a throat or constricted passage 55 through which all the material must pass in its journey through the mixer.

The tuyre F is connected by pipes 55, 56, to a supply tank G which is adapted to contain air under pressure obtained from any suitable source. A control valve 57 is positioned in the pipe line and controls the amount of air'delivered from the supply tank G to the tuyere F. opens into the lower pocket or basin d9 of the chamber 13' and injects the air or other gas into the chamber along the bottom til so as to thoroughly encounter all of the material that has come into the mixer from the ladle C. The fact that the passageway 54 is a constricted passageway improves the operation of the mixer. It insures that the gas delivered by the tuyere will encounter directly or indirectly all the particles of fuel E that have been delivered into the hopper ll.

It will be noted that the fuel in this instance is dropped into the hopper ll and preferably at a point where it will fall toward the constricted i opening 58. If the fuel packets E, as before,'are

Whatever The latter been thrown into thehopper, insures a good mixture of the non-combustible slag and the com bustible fuel as the same passes down into the smaller chamber 52 in which it begins to encounter the supply of gases from the tuyre.

Obviously as the mixture of combustible and non-combustible material passes downward and on through the constricted passage 54, it will be acted upon by the oxygen of the supply throughthe tuyere and combustion will result. The latter will occur wherever there is a particle of fuel, and wherever it does occur there will result a multi plicity of gaseous bubbles which will increase the foam structure of the mass. As the intermingled oxygen and fuel and non-combustible slag material rises through the passage 50, the combustion can proceed at all points and there will be, by reason of the vertically upward flow, a greater possibility of all liquid material being intermingled with the bubbles and therefore used up in making the foam structure which is desired as, the product of the process.

As before suggested, the'combustion raises the temperature ofthe hot slag and lessens the viscosity, thereby promoting the formation of the foam mixture. The length and rise of the pas sage or chamber '50 in which so great combustion takes place, are gauged to suit the viscosity that may be desired, the longer the chamber the greater the puffing up of the slag and the greater the certainty it will arrive at the desired mixture.

As before indicated, the hopper L and the associated chute 60 may be used for the delivery of combustible and non-combustible material K into the outlet spout of the hopper B. In this way the character of the product issuing from the mixer may be to a certain extent controlled.

The hopper B in the embodiment illustrated is carried upon channel irons 6| supported by suitable posts 62, 63, 6 3, 65. These, in turn. rest upon a concrete foundation 66 upon the ground 67. The foundation 66 is provided with a pit 68 below the outlet 69 of the mixer B. The purpose of the pit is to receive in a bath of water the contents of the mixer when the latter is dumped by opening the stopper valve ll! which normally closes the opening 69. The passage of the slag into the water breaks up or granulates the slag and then it can be shoveled easily from the pit. The stopper I0 is normally held in closed position by a series of weights ll positioned on the free end of the supporting arm 12 which is pivoted to the structure at an intermediate point 13 and has an upturned end which is secured loosely to the stopper ll Granulated slag, produced as just stated or otherwise, may be used as one of the non-combustible materials K delivered into the outlet spout of the hopper B. Being non-combustible it tends to cool the mass. But it should be understood that the cooling effect may be produced in other ways.

The fuel packets E, as before indicated, may be fed into the mixing chamber B in any suitable way. If desired, this can be done by hand. It is preferred, however, to employ some mechanism for doing this at a regular rate. For this purpose in the embodiment in question a hopper I6 is located near the receiving mouth of the mixer B but preferably a little to one side of the same so as to not interfere with the emptying of the slag from the ladies -nto the mixer. A

trough ll leads from the lower end of the hopper l6 and its open end is directly above the mouth the constricted throat 48 of the same.

For the purpose of feeding the fuel to the hopper 16 in proper quantities and at a proper rate, the elevatorH is employed. This includes a belt I8 traveling over suitable wheels-l9, 88', properly journaled in a supporting frame BI carried upon uprights 82, 83, extending upward from the foundation 65.

.The conveyor H may be driven in any suitable way as by an electric motor 84 mounted upon the' foundation 66 adjacent to the lower end of the conveyor. A belt 85 transmits power from the shaft of the motor to the pulley on the shaft of the lower wheel 88. The belt I8 carries flights 88 or other suitable devices for receiving and holding the packets E of fuel which are arranged to drop from a hopper 86 of the mechanism J at suited intervals. The hopper J is carried in any suitable way, as by means of the uprights 81. In this particular instance no special means is shown for feeding the packages E from the hopper 86 in timed relation with the travel of the belt l8 but obviously this might be done by controlling the outlet of the hopper 86 by hand or other suitable mechanism that would insurethe deposit of the requisite number of packets, one or more, upon each'fiight 88.

As the molten masspasses over the delivery lip SI of the mixer B, it is also moved in a more or less vertical direction and this assists, as it did in the upward movement of the mass through the channel 58, in equalizing the distribution of the gaseous bubbles in the mass which is on its way to the conveyor P. Any combustion which may take place at this time will thus more evenly distributethe bubbles than if the direction of travel were more nearly horizontal. The result of this even distribution-of the bubbles through out the mass is a more uniform cellular structure in the product.

Tofurther'assist in fixing the character of the ultimate product it may be desirable in some instances to agitate the mass just after it leaves the mixer B and just as it enters upon the conveyor P. Obviously a hand stirring device or tool might be used for this purpose. It is, however, preferable to employ some mechanical stirrer. Such mechanism is the stirring mechanism M. The latter includes a pair of vertical shafts 98 with stirring blades 9| at their lower ends. These shafts are suitably journaled in bearings 921 carried by a suitable frame member 93. For the purpose of rotating the shafts theyare provided with bevel gear wheels 94 which cooperate with bevel gear wheels'95 carried by a horizontal shaft 96. 'Ihei'latter is suitably iournaled in bearings S'I'upon-the frame member 93. The shaft 96 is extended and carries at its outer end a free running pulley 98 to which it may be secured at will by an associated clutch 99. The pulley 98 is suitably driven through a belt I88. Whenever it is desired touse a stirring device the clutch 99 is operated so as to connect the driving pulley 98 to the shaft 96. Whenever it is necessaryto stop the stirring, then the clutch 99 is thrown in the opposite direction to disconnect thepulley 98 from the shaft 96.

The conveyor belt P extends substantially horizontally and travels over e'nd rollers I83, I84, suit;

ably journaled in bearings carried by pedestals I85, I86, which find their support in the foundation 66. The upper stretch of the belt P travels the belt P a. series of perforations I I9.

47 of the mixer. Fuel deposited in the hopper at over guides I87 and rather closely engages them. The guides I8'I are supported by suitable legs I88, I89, cross members 8 and longitudinal bracing members I I I. The legs in this case rest also upon the foundation 66. As'shown, the receiving end of the belt P is located well beneath the spout 5| of the mixing chamber B. present instance shown as driven by an electric motor II2 which operates through a belt 3 upon a drivin pulley II4 upon the shaft of the roller I84. The direction of travel of the belt is such that its upper strand travels outward away from the chamber B.

In order that the slag material may not stick to the surface of the belt P, some separating material such as sand or granulated slag or glass should be thrown upon the surface of the belt at the receiving end. of its upper stretch. As before indicated, this may be done by hand, but preferably some mechanism is employed for the purpose. In the present instances, a distributor such as shown more'particularly in Fig. 4 is employed.

This distributor U includes a cylindrical casing II8 having in its lower side adjacent to Through the cnter of this casing IIB extends a shaft I28. This shaft carries a spiral conveyor I 2! which travels so as to carry material from right to left, as the parts are shown in Fig. 4.. The receiving end of the sander is provided with a The belt'is in the' hopper I2I into which the material which is to be used as the separating material upon the conveyor may be deposited. An outlet I22 is controlled in size by a slide I23. In this way the amount of granulated material which passes into the cylinder II8 may be regulated and the movement of the conveyor I2I will early the same through the cylinder and it will pass out through the perforations 9 on to the upper surface of the upper stretch of the conveyor P. The spiral conveyor IZI is driven through the agency of a pulley I24 on the shaft I 28 driven by a belt I25 extending over the driving pulley I26 of an electric motor I21 suitably supported on the foundation 66.

The mass of slag, as it passes out upon the conveyor P, is in a foamy plastic condition and capable of being molded and shaped into a suitable slab which advances continuously. For the purpose of restrictingthe slab to a proper width, a pair of edging rollers is mounted to rotate in the plane of the advancing slag strip. The.

to substitute for one of the rollers I28 a roller I28 provided with a groove I29.

edge wheels in Fig. 8. A similar product is the block S of Fig. 9. T

These edge rollers, whichever pair is used, are

mounted, as illustrated more particularly in the case of the rollers I28, uponvertical shafts I3I- journaled in suitable arms I32 upon pedestals I33 carried by the foundation 66. Bevel wheels I34, I35 upon the shafts I3I and a common driving shaft I 36 cooperate in driving the edge In such case a slab is provided with a regular tongue and groove as illustrated in the piece between the rollers from the shaft I36. The latter, as shown is suitably journaled in bearings in uprights I31 .'upon thestandards I33. The shaft I36 is provided at one end with a driving pulley I38 which is driven through the agency of a belt I39 from the pulley hill of an electric motor I lI. Obviously other ways of driving the edge rollers may be employed but the way shown will suflice for the present disclosure.

At this point it may be noted that the belt Iflt which drives the pulley 96 upon the driving shaft of the stirring mechanism M, is driven from a pulley I62 mounted upon the shaft 136 alongside of the pulley I38. Thus both stirring mechanism M and edging mechanism Q are operated from the same driving motor MI.

The element which controls the thickness of the slab is located nearer the outlet of the mixer.

7 At one point in its periphery the roller R is provided with a longitudinal rib I lI. This rib by encountering the slag material at regular intervals produces a crease orgroove I8 which extends transversely of the slag. These grooves I66 occur at regular intervals and the diameter of the roller R is chosen with a view to fixin the distance between successive grooves. Obviously, instead of producing the creases I68 by the rib I I? on the gauging roller R, the creases mi ht be made upon the slab web by any suitable tool, operated either by hand or mechanism. The driving shaft I66 of the roller R is provided at one end with a driving pulley I58. This pulley may be driven in any suitable way as by means of the belt II which passes over a driving} pulley I52 located at the end of a shaft I53 suitably journaled in bearings at the upper ends of standards I6 5. The shaft I53 is driven in turn by a belt I 55 which engages cooperating pulleys I56 and I5? on the shaft I53 and the shaft of the driving motor I iI, respectively.

The'shaft I53 carries a roller I58 which is provided with a number of rows of teeth I59. These. teeth come close to the surface of the slab strip and comb the surface. The result of this power combing of the surface is to break down the outer walls of the cells along the top of the strip and cause the same to more or less close over the various cellular openings and thus provide akind of roughness at the outer surface of the slab, well suited to receive and hold a coat of plaster or the like. Obviously, this combing may be done in longitudinal strips by providing the teeth I59 in groups along the roller I56. Again, the combing may be done by any suitable tool operated by hand or by other mechanism than shown. 7

It will be seen that as the slab web is advanced by the conveyor P it will'gradually cool and the formed slab will retain its shape in cross-section. Thelength of the belt may be made such that the slab will be sufficiently cool by the time the delivery end of the conveyor is reached, that the protruding end of the web will break off along the line of the nearest crease I68 and thus produce a series of slabs S, which are indicated particularly in Fig. l as carried upon a car I62 having wheels I63 traveling on suitable track rails I66, in this and need not be illustrated.

by the edging mechanism Q all occur while the foam mass is still plastic, while the final breaking off at the end of the conveyor P after the mass has become cool enough to be fragile and readily breakable along the creased lines.

As previously indicated, the resulting product is a series of slabs of cellular formation having plain or variously shaped edges. Thus, there may be grooves I30 in each of the edges; or, if desired, a groove I36 may be placed in one edge and a tongue I66 upon the other edge. Still other edge formations may be provided.

In furtherance of the invention, the double grooved slab or block S may be used to build up a tongue and groove structure by placing in one of the grooves a projecting strip I65 which will project far enough beyond the edge to form a tongue adapted to fit into thegroove I36 of a like tongued and grooved block. This is the struc ture particularly illustrated in Fig. 6.

Instead of putting strips of this kind into the groove, it may be desirable forsome building purposes to reinforce the block. In such case, metal bars or rods I66 are placed in the respective grooves I30, and when pressed against the bottoms of the same, a filling of cement I61, or other like material, is employed to enclose and firmly hold the reinforcing rods. This is a structure more particularly shown in Fig. '7.

As shown in Fig. and in other figures too, the exterior surfaces 20 205 of a product block close over the main cells of the foam structure and where the end is cut off or broken off, the cells are left exposed for finishing or coating or other treatment, as desired. Where the closed over surfaces 20 3, 205 are desired, it is only necessary to roll or otherwise similarly treat the surface of r the slag as it passes along in the course of manufacturing the slabs. This rolling operation smooths down the cells near the surface and allows the contained bubbles to elongate and the adjacent walls to run together to provide the outside skin which makes the finished surfaces 2%,

might also be given a different diameter to vary the length of the slab. The same result might be had in other instances by giving a roller R of given diameter a different number of creasing bars Il'i. If the roller R is to be vertically adjustable then it can be made so in the same manner as the upper roll of a two high mill is made adjustable. Such constructions are well known Obviously too, the edging rollers I28, I28, I29 may be varied in position in order to produce different widths of slabs. This can be done'by adjusting one or both of the rollers horizontally toward and from each other like the edging rollers of a universal mill. Again, the edges of these rollers may themselves be varied to provide vari-,- ous shaped designed to interfit with each other or otherwise, as desired.

but aim to cover by the terms of the appended claims all those alterations and modifications which rightly come within the purview of the invention.

I claim:

1. In a process of the kind described, the operations of delivering a stream-of hot bubbly material of the kind described upon a continuously traveling conveyor and subjecting the same while on the conveyor to a cooling action, whereby the material on the conveyor at any given instant constitutes a traveling mass which is in a semimolten plastic state at the receiving point and gradually cooler down to the delivery point where it is cooled to solidity, accompanied by the application of rolling pressure to the hot mass near said receiving point to smooth down the cells near the surface of the material and allow the contained bubbles to elongate and the adjacent walls to run together to provide an outside skin, and

subsequently raking the outside surface thus formed after the same has been somewhat cooled but before it reaches its fully cooled state to break down the outer cell walls and permit the material more 'or less to close over the various cellular openings and thus provide a roughness upon the product surface well suited to receive a coat of plasterer the like.

2. In a process of the kind described, the operations of delivering a stream of hot bubbly material of the kind described upon a continuously traveling conveyor and subjecting the same while on the conveyor to a cooling action whereby the material on the conveyor at any given instant constitutes a traveling mass which is in a semi- -molten plastic state at the receiving point and progressively cooler down to the delivery point where it is cooled to solidity, accompanied by the operations of pressing the material of the stream stream to cool as it advances, thus providing at' any given instant a length of material of varying temperatures ranging from that of the hot plastic mass at one end progressively down through lower temperatures to that of the cooled solid product at the other end, and raking the surface of the stream at an intermediate point in said length to break down the previously formed cell walls and thus produce a roughened surface in the finished cooled product.

WILLIAM C. CORYELL. 

